Making 1 from 2 - my new bongo project

[thomp1983]

Hi all,

Long time lurker, rare poster here. In March I'm about to embark on a new bongo project which I thought I'd document here (not sure if this is the best section, feel free to move.)

viewtopic.php?t=78632

Thats a link to my original introduction thread when I entered bongo ownership and also contains an update of what I'm planning.

The short version is I bought a rusty bongo did nothing about repairing it for 3 years then I've just bought a solid bongo with a broken engine so I'm putting the engine from the rusty one into the other one.

That's the rusty one there, looks quite deceptive but drivers sill has gone completely all, the way up into the main floor.

That's the engine and box out of the rusty one, it took me and a mate 5 hours to remove but I was rather brutal in cutting anything that didn't want to come undone, I will need to be alot more careful with the new chassis which means it'll be alot longer.

The rusty one making it's final journey.

[thomp1983]

Enter the new bongo, she's got a few marks but given the age I'm fine with that.

I plan to remove the broken engine and box in March, this will be followed by a good look at the chassis which. I'll do any necessary repairs on and under seal.

The new engine and box will go in and then I should hopefully be good to go for the summer, I kept a few bits off my old bongo that were in better condition so they'll also get fitted.

I'm currently building a service shopping list for the donor engine which comprises the below,

Timing belt kit,
Water pump,
New valve cover gaskets,
Cam and crank seals,
Air/fuel/oil filters,
Spark plugs,
Thermostat,
Low coolant alarm,
Self bleeding kit,

Most of that will be fitted to the donor engine whilst it's out the vehicle as access is so much easier, I also plan to remove the transmission and get as much old fluid out of it as possible including the torque convertor.

So as you can see I've a bit on but I've alot less on outside of this now unlike before when I was still building extensions.

Thanks,
Chris

[thomp1983]

Hello again,

So it stayed dry today so I decided I'd have a look at disconnecting the various bits that connect the engine and gearbox to the chassis and have a general poke around.

That's the broken engine that shall be removed before I removed anything,

I managed to get everything off the top side quicker than I thought so I proceeded to put her on my new high lift axle stands,

With her safely raised I then removed everything from the underside

That also went surprisingly well, I'm now left with just the gearbox oil to drain, the propshaft to remove and the gearbox/engine stay mounts to undo and she'll be out.

I'm fairly sure that once I get my big jack out I can raise the chassis high enough that I can drop the engine/box onto a crawler board and slide it out in one go, when I took the other engine out in my garage I didn't have these taller stands and the dolly I dropped it onto was alot taller so I had to take the inlet manifold off the top to clear the sill..

Not many pictures I'm afraid, I'll take them once everythings out but on first inspections everything is really good and solid under there, a couple of the metal coolant lines will need either replacing or repairing but that's about it hopefully.

Thanks,
Chris.